Chapter 5 Overview - PowerPoint PPT Presentation

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Chapter 5 Overview

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Chapter 5 Overview Casting die is the other major component Casting die has four functions: Hold molten metal in shape of desired casting Provide means for molten ... – PowerPoint PPT presentation

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Title: Chapter 5 Overview


1
Chapter 5 Overview
  • Casting die is the other major component
  • Casting die has four functions
  • Hold molten metal in shape of desired casting
  • Provide means for molten metal to get into the
    space where it is held in desired shape
  • Remove heat from molten metal to solidify it
  • Provide for removal of the solidified metal

2
Chapter 5 Objectives
  • Identify the four types of casting dies
  • Identify the three major casting die modules
  • Identify the purpose of each major die component

3
New Terms
  • Cavity
  • The void or empty space in the die that fills
    with metal to make the casting
  • Gate
  • The smallest restriction in the alloy flow path,
    located at the edge of the casting
  • OEM
  • Acronym for Original Equipment Manufacturer
  • Overflows/lifters
  • Small pockets of alloy located around the edge of
    the casting

4
New Terms cont.
  • Runner
  • Die cast alloy distribution system within the
    casting die
  • Shot
  • All the injected material
  • Vacuum vent
  • Helps get the air out of the die cavity.
  • Vent
  • Path from the die cavity to outside the die

5
Die Ownership
  • The OEM owns the tooling required to make the die
    casting
  • If GM opted to purchase casting from a custom
    producer, the custom producer would buy casting
    die from a toolmaker and then sell the die to GM
  • If GM opted to manufacturer the casting in its
    own plant, GM would buy the die from a toolmaker
    directly

6
Types of Dies
  • Single cavity die
  • Produces one casting at a time
  • Multiple cavity die
  • Produces more than one casting at a time
  • Family die
  • Produces a number of different parts
  • Unit die
  • OEM owns the unit die and the custom die caster
    owns the mold base or unit die holder

7
Unit Die System
  • Advantages
  • Lower tooling costs
  • Shorter lead times
  • Potentially lower piece part costs
  • Disadvantages
  • Reduced flexibility in part design
  • Limited size
  • Possible problem moving tooling from one vendor
    to another without additional tooling costs

8
Mold base
  • Steel envelope that is designed to hold all the
    other die components together
  • Usually made from a pre-hardened steel such as a
    P-20 or AISI 4140

9
Stationary half mold base
  • Acts as container for stationary die cavities
  • Provides means for attaching stationary die half
    to machine
  • Couples injection system to the die
  • Provides a means for aligning to two die halves
  • Has several components

10
Stationary Half MoldBase Components
  • Clamp slots
  • Guide pins
  • Pryslots
  • Mounting/clamp plate

11
Moving half mold base
  • Acts as container for the die cavities
  • Couples ejection system to the cavities
  • Provides means for aligning the two die halves
  • Components include
  • Guide bushings

12
Ejector box
  • Provides a means for mounting moving half mold
    base to moving machine platen
  • Supports moving half mold base against machine
    closing force and force of injection
  • Couples machine ejector system to die ejector
    system
  • Has several components

13
Ejector Box Components
  • Parallels/rails
  • Clamp plate
  • Support pillars

14
Ejector system
  • Inside the ejector box
  • Provides one of four critical die functions, to
    provide for removal of the solidified metal
  • Has several components

15
Ejector System Components
  • Ejector pins
  • Return pins
  • Ejector plate
  • Ejector return plate
  • Guided ejection

16
Die Cavity
  • Cavity blocks
  • Core pins
  • Slides
  • Carrier
  • Wedgelock
  • Cam pin
  • Cooling lines
  • Heaters

17
Die Cavity cont.
  • Several cavity features share same terminology as
    the die cast shot
  • Sprue
  • Runner
  • Gate
  • Overflows
  • Vents

18
Miscellaneous Components
  • Biscuit block
  • Sprue bushing
  • Sprue post
  • Stop buttons
  • Quick eject cam and pins

19
Summary
  • Casting die is the other major component
  • Has four functions
  • Castings can be manufactured by the OEM or
    purchased from a custom producer
  • 4 casting die forms single cavity, multiple
    cavity, family and unit
  • A typical die contains 3 modules stationary mold
    base, moving mold base and ejector box

20
Summary cont.
  • Unit dies are not complete dies have certain
    advantages and disadvantages for the OEM
  • There are many components to casting dies
  • Mold base
  • Stationary half mold base
  • Moving half mold base
  • Ejector box
  • Ejector system
  • Die cavities
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